WO2017055731A1 - Corrosion-resistant starter rotor for a motor vehicle - Google Patents

Corrosion-resistant starter rotor for a motor vehicle Download PDF

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Publication number
WO2017055731A1
WO2017055731A1 PCT/FR2016/052449 FR2016052449W WO2017055731A1 WO 2017055731 A1 WO2017055731 A1 WO 2017055731A1 FR 2016052449 W FR2016052449 W FR 2016052449W WO 2017055731 A1 WO2017055731 A1 WO 2017055731A1
Authority
WO
WIPO (PCT)
Prior art keywords
conductor
alloy
rotor
contact
rotor according
Prior art date
Application number
PCT/FR2016/052449
Other languages
French (fr)
Inventor
Eric Vernay
Benoît BALEYDIER
Pascal Jacquin
Jean Sébastien Metral
Gauthier VIGY
Original Assignee
Valeo Equipements Electriques Moteur
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from FR1559110A external-priority patent/FR3041829A1/en
Priority claimed from FR1559108A external-priority patent/FR3041828A1/en
Application filed by Valeo Equipements Electriques Moteur filed Critical Valeo Equipements Electriques Moteur
Publication of WO2017055731A1 publication Critical patent/WO2017055731A1/en

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/04—Details of the magnetic circuit characterised by the material used for insulating the magnetic circuit or parts thereof
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K13/00—Structural associations of current collectors with motors or generators, e.g. brush mounting plates or connections to windings; Disposition of current collectors in motors or generators; Arrangements for improving commutation
    • H02K13/006—Structural associations of commutators
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K13/00—Structural associations of current collectors with motors or generators, e.g. brush mounting plates or connections to windings; Disposition of current collectors in motors or generators; Arrangements for improving commutation
    • H02K13/04—Connections between commutator segments and windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/02—Windings characterised by the conductor material
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/26—Rotor cores with slots for windings
    • H02K1/265—Shape, form or location of the slots
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K23/00—DC commutator motors or generators having mechanical commutator; Universal AC/DC commutator motors
    • H02K23/26—DC commutator motors or generators having mechanical commutator; Universal AC/DC commutator motors characterised by the armature windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/006—Structural association of a motor or generator with the drive train of a motor vehicle

Definitions

  • the present invention relates to a starter rotor for a motor vehicle resistant to corrosion.
  • Starters for a motor vehicle having a stator, or inductor, comprising several permanent magnets or coiled poles (electromagnets) and a rotor, or an inductor having a cylindrical body and a formed winding are known. by drivers.
  • An air gap exists between the outer periphery of the rotor body and the inner periphery of the stator.
  • the rotor body consisting of a bundle of sheets has longitudinal notches. To form the winding, pin-shaped conductors are threaded into the notches generally on two separate layers.
  • the rotor further comprises a collector provided with electrically conductive blades made of copper which extend side by side on the outer periphery of a support made of plastic material. These conductive blades are intended to cooperate with brushes of the electric motor.
  • Each of the blades comprises a housing in which at least one end of the winding conductors is positioned to be in contact with the corresponding blade.
  • the connection between the blades and the conductors is generally performed by welding.
  • a study of the process of assembling aluminum conductors on the collector has revealed a significant risk of corrosion of the connection between the blades and the ends of the winding conductors. This corrosion is likely to cause mechanical fragility and an increase in electrical resistance, or electrical insulation at the connections. This risk is even more important in the case of a saline atmosphere.
  • the invention aims to effectively remedy this disadvantage by proposing a starter rotor for a motor vehicle comprising: a body and a coil formed by aluminum conductors installed in notches of said body,
  • a collector comprising copper contact strips and a support made of insulating material
  • said contact blades being isolated from each other by a part of said support
  • said contact blades each comprising a first portion intended to be in contact with brushes and a second portion comprising a housing receiving an end of at least one conductor, characterized in that a layer of an alloy is interposed in said a housing between each conductor and each corresponding contact blade, said alloy being a conductive alloy having physical properties for reducing electrochemical coupling between copper and aluminum.
  • said alloy comprises tin. This makes it possible to have an alloy that has good property concerning corrosion avoiding the increase of the electrical resistance between copper and aluminum.
  • the alloy layer covers at least one stripped portion of the conductor whose length is preferably greater than the length of the conductor section located in the corresponding housing. This makes it possible to ensure that the portion of the stripped section does not come into contact with the collector directly.
  • each first portion of said contact blades extends axially with respect to an axis of said rotor. This allows the wear dust of the brushes to escape by centrifugal force.
  • each first portion of said contact blades extends radially with respect to an axis of said rotor. This makes it possible to have a lower axial size starter.
  • said housing is closed at least in part by edges of contact blades folded towards the at least one conductor. This makes it possible to ensure electrical contact between the collector and the conductor coated with the alloy and to keep the conductors in the slots despite the centrifugal force.
  • said second portions of said contact blades each comprise traces of hot deformation. This improves the folding of the blade on the driver. Indeed, there is need for less force when punching hot than cold.
  • said alloy layer comprises bronze and tin. This allows for a certain electric motor not sufficiently dissipating the calories, to withstand a melting temperature of the tin during operation at high temperature for example due to the intensive use of a starter for example in a traffic jam.
  • said at least one conductor comprises at least one bare section having a length greater than a length of a portion of said conductor located in said housing of said second portion of said corresponding contact blade, and in that said at least one bare section is covered with said alloy. This ensures that the entire bare section of copper contact is covered with tin to prevent corrosion.
  • said at least one conductor comprises an anodized aluminum layer and in that said stripped section is devoid of this anodized aluminum layer. This avoids having to add a resin on the conductor to electrically isolate it from the sheet package.
  • said at least one conductor comprises a layer of enamel or resin for example epoxy and in that said bare section is devoid of this layer of enamel.
  • a thickness of said alloy layer is between 3 ⁇ and 20 ⁇ and particularly between 5 m and 12 ⁇ .
  • the invention also relates to a motor vehicle engine starter having a rotor as previously defined.
  • a collector comprising copper contact strips and a support made of insulating material
  • said contact blades being isolated from each other by a part of said support
  • said contact blades each comprising a first axially extending portion intended to be in contact with brushes and a second portion comprising a housing receiving an end of at least one conductor
  • a layer of an alloy covers at least faces of said contact blade forming said housing and in that said alloy layer is in contact with said at least one aluminum conductor, said alloy being an alloy conductor having physical properties for reducing electrochemical coupling between copper and aluminum.
  • the invention thus makes it possible to break the direct contact between the copper of the collector and the aluminum of the conductors, which makes it possible to limit the corrosion of the connection between the contact strips and the ends of the winding conductors. This increases the life of the starter.
  • a face of the contact blades vis-à-vis said rotor body is covered with said alloy layer. This prevents corrosion on this face of the collector which is difficult to access when the conductors are in the notches.
  • all the faces of the blades other than the faces in contact with said support of said collector are covered an alloy layer. This ensures the alloy between the conductor and the blades.
  • said alloy comprises tin.
  • each first portion of said contact blades extends axially with respect to an axis of said rotor. This allows the wear dust of the brushes to escape by centrifugal force.
  • each first portion of said contact blades extends radially with respect to an axis of said rotor. This makes it possible to have a lower axial size starter.
  • said housing is closed at least in part by edges of contact blades folded towards the at least one conductor. This makes it possible to ensure electrical contact between the collector and the conductor coated with the alloy and to keep the conductors in the slots despite the centrifugal force.
  • said second portions of said contact blades each comprise traces of hot deformation. This improves the folding of the blade on the driver. Indeed, there is need for less force when punching hot than cold.
  • said alloy layer comprises bronze and tin. This allows for a certain electric motor not sufficiently dissipating the calories, to withstand a melting temperature of the tin during operation at high temperature for example due to the intensive use of a starter for example in a traffic jam.
  • a thickness of said alloy layer is between 8 ⁇ and 30 ⁇ and more particularly between 12 m and 20 ⁇ . Indeed below 8 ⁇ there is a risk, when inserting the conductor in the notch, that the tin is removed and therefore there is a direct contact between aluminum and copper.
  • Figure 1 shows a perspective view of a starter rotor according to the present invention
  • Figure 2 is a side view of the starter rotor according to the present invention.
  • Figure 3 is a longitudinal sectional view of the starter rotor according to the present invention.
  • Figure 4 is a schematic representation illustrating the two layers of conductors positioned within the notches of the rotor body
  • Fig. 5 is a schematic representation illustrating the connection between conductors and a corresponding contact blade in a starter rotor according to the present invention
  • Figure 6 is a schematic representation of a conductor used in the starter rotor according to the present invention.
  • Figures 1 to 3 show an X-axis rotor 10 having a body 1 1 mounted on a shaft 12.
  • This body 1 1 in the form of pack of laminated sheets has an outer periphery of cylindrical shape.
  • Notches 14 are formed longitudinally at the outer periphery of the body 1 1.
  • a set of conductors 13 are threaded inside these notches 14.
  • each conductor 13 made of aluminum has an anodized aluminum surface layer 39 at its surface.
  • Each conductor 13 is further coated with an electrically insulating layer 15, such as enamel for its insulation.
  • Each driver 13 has two branches 131, 132 connected by a bottom 133 so as to form a U (see Figure 6).
  • the conductors 13 are threaded inside the notches 14 on two distinct layers: the upper layer and the lower layer. If one of the branches 131, 132 is positioned in the lower layer of a given notch then the other leg 131, 132 is in the upper layer of another notch and vice versa.
  • the section of the conductors 13 may be round, square, or rectangular.
  • a notch insulator 18 is positioned around the branches 131, 132 of the conductors 13. In this case, this insulator 18 has an S-shaped section. This insulator 18 makes it possible not to injure the conductors 13 during their assembly in the body 1 1 formed by the bundle of sheets of the rotor 10 provided by definition of burrs. This also electrically insulates the conductors 13 from the grounded package of sheets via the starter housing. The clearance between the insulator 18 and the edges of the notches 14 is filled with an impregnating varnish.
  • the rotor 10 further comprises a collector 19 provided with electrically conductive blades 20 which extend side by side on an outer periphery of an electrically insulating support 23 which is clearly visible in FIG. 3.
  • the contact strips 20 are isolated from each other. other by a portion of the support 23.
  • the support 23 secured to the shaft is, for good temperature resistance, thermosetting plastic material, such as a thermosetting phenolic plastic material for example Bakelite.
  • the conductive blades 20 each comprise a first portion 21 extending substantially axially along the X axis of the rotor 10 and intended to be in contact with radially oriented electric motor brushes (not shown).
  • the conductive blades 20 also comprise a second portion 22 having a radial orientation with respect to the X axis of the rotor.
  • the set of second portions 22 forms the heel 28 of the collector 19.
  • Each second blade portion 22 comprises a housing 25 in which two sections 41 of the conductors 13 of the rotor winding 10 are positioned to be in contact with the corresponding conductive blade 20 (see Figure 5).
  • the sections 41 positioned inside the housings 25 are constituted by a portion of the free ends of branches 131, 132 of two different conductors.
  • a layer 35 of an alloy is interposed in the housing 25 between each conductor 13 and the corresponding contact blade 20.
  • the alloy is a conductive alloy having physical properties to reduce electrochemical coupling between copper (blades 20) and aluminum (conductors 13).
  • the alloy comprises tin.
  • a thickness of the alloy layer 35 is between 3 ⁇ and 20 ⁇ and particularly between 5 ⁇ and 12 m
  • the alloy layer 35 covers at least one stripped section 40 of the conductor 13, the length of which is preferably greater than the length of the section 41 of the conductor located in the corresponding housing 25.
  • the conductor 13 is stripped at its ends with the aid of sandpaper or a stripping plier on a length of the order of 1 cm.
  • the stripped portion 40 is thus devoid of the thin insulating anodized aluminum layer 39 and the enamel layer 15, so that the alloy layer 35 is deposited directly on the copper constituting the conductor.
  • the conductors 13 are tempered, for example, in tin heated to its melting point (of the order of 230.degree. C.), which will slide on the enamel 15 to cover only the bare sections 40 of the conductors. 13.
  • the electrical connections between the conductors 13 and the second portions of the blades 22 are preferably made by a so-called hot punching method of heating the bead 28. by means of an electrode so as to fold down an edge of the blade portions 22 after insertion of the sections 41 of the conductors 13 into the housings 25. As shown in FIG. 5, the conductors 13 are then retained in each housing 25 by material 45 of the second blade portions 22 deformed hot to the conductors 13 so as to close the housing 25.
  • the electrical connections between the conductors 13 and the blades 20 are performed by a method of welding by ultrasound or resistance.
  • the alloy layer 35 comprises tin and bronze resulting from mixing between a portion of the tin covering the conductor and a part of the copper of the blade.
  • the conductors 13 are retained in the housing 25 by punching.
  • each contact blade 20 extends radially relative to the axis X of the rotor 10 so as to cooperate with brushes oriented axially with respect to the axis X.
  • frets 30, 31, 32 electrically insulating material are mounted tightly around the electrical connections and winding bignons located on either side of the body of the rotor 1 January.
  • the rotor 10 may further comprise at one end of its shaft 12 a gear wheel 33 located on the opposite side of the collector 19 and intended to form a sun gear in a planetary gear reduction system of a starter, as described for example in the document FR2787833.
  • a single winding conductor 13 is positioned per housing 25.
  • the invention also relates to the starter equipped with the rotor 10 described above.
  • the starter further comprises a stator comprising a coil or magnets for forming the poles of the inductor.
  • the starter further comprises an actuator comprising a movable contact plate that moves to a closed position connecting two contact terminals, one of which is connected to the battery and the other connected to the collector brushes and to the induction coil if the stator comprises an inductor winding.
  • the starter rotor for a motor vehicle comprises:
  • a collector comprising copper contact strips and a support made of insulating material
  • said contact blades being isolated from each other by a part of said support
  • said contact blades each comprising a first axially extending portion intended to be in contact with brushes and a second portion comprising a housing receiving an end of at least one conductor
  • a layer of an alloy covers at least faces of said contact blade forming said housing and in that said alloy layer is in contact with said at least one aluminum conductor, said alloy being an alloy conductor having physical properties for reducing electrochemical coupling between copper and aluminum.
  • the invention thus makes it possible to break the direct contact between the copper of the collector and the aluminum of the conductors, which makes it possible to limit the corrosion of the connection between the contact strips and the ends of the winding conductors. This increases the life of the starter.
  • alloy is meant an alloy that does not include a majority of aluminum and / or copper.
  • a face of the contact blades vis-à-vis said rotor body is covered with said alloy layer. This prevents corrosion on this face of the collector which is difficult to access when the conductors are in the notches.
  • all the faces of the blades other than the faces in contact with said support of said collector are covered with an alloy layer. This ensures the alloy between the conductor and the blades.
  • said alloy comprises tin.
  • each first portion of said contact blades extends axially with respect to an axis of said rotor. This allows the wear dust of the brushes to escape by centrifugal force.
  • each first portion of said contact blades extends radially with respect to an axis of said rotor. This makes it possible to have a lower axial size starter.
  • said housing is closed at least in part by edges of contact blades folded towards the at least one conductor. This makes it possible to ensure electrical contact between the collector and the conductor coated with the alloy and to keep the conductors in the slots despite the centrifugal force.
  • said second portions of said contact blades each comprise traces of hot deformation. This improves the folding of the blade on the driver. Indeed, there is need for less force when punching hot than cold.
  • said alloy layer comprises bronze and tin. This allows for a certain electric motor not sufficiently dissipating the calories, to withstand a melting temperature of the tin during operation at high temperature for example due to the intensive use of a starter for example in a traffic jam.
  • a thickness of said alloy layer is between 8 ⁇ and 30 ⁇ and more particularly between 12 ⁇ and 20 ⁇ . Indeed below 8 ⁇ there is a risk, when inserting the conductor in the notch, that the tin is removed and therefore there is a direct contact between aluminum and copper. Indeed, above 12 ⁇ , there is more risk of direct contact between aluminum and copper.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Windings For Motors And Generators (AREA)
  • Motor Or Generator Current Collectors (AREA)

Abstract

The invention relates essentially to a rotor (10) of a motor vehicle starter, comprising a body (11) and a winding formed by aluminium conductors (13) mounted in slots (14) in said body (11), a commutator (19) comprising copper contact blades (20) and a support member (23) made of an insulating material, wherein the contact blades (20) are insulated from each other by a portion of said support member (23), and the contact blades (20) each have a first portion (21) for contacting brushes and a second portion (22) comprising a recess (25) receiving one end of at least one conductor (13). An alloy layer (35) is inserted in said recess (25), between each conductor (13) and each corresponding contact blade (20), said alloy being a conductive alloy having physical properties suitable for reducing electrochemical coupling between the copper and the aluminum.

Description

ROTOR DE DEMARREUR POUR VEHICULE AUTOMOBILE  STARTER ROTOR FOR MOTOR VEHICLE
RESISTANT A LA CORROSION  CORROSION RESISTANT
La présente invention porte sur un rotor de démarreur pour véhicule automobile résistant à la corrosion. On connaît des démarreurs pour véhicule automobile munis d'un stator, ou inducteur, comportant plusieurs aimants permanents ou des pôles bobinés (électroaimants) et d'un rotor, ou induit, doté d'un corps de forme cylindrique et d'un bobinage formé par des conducteurs. Un entrefer existe entre la périphérie externe du corps du rotor et la périphérie interne du stator. Le corps du rotor consistant en un paquet de tôles présente des encoches longitudinales. Pour former le bobinage, des conducteurs en forme d'épingle sont enfilés à l'intérieur des encoches généralement sur deux couches distinctes. The present invention relates to a starter rotor for a motor vehicle resistant to corrosion. Starters for a motor vehicle having a stator, or inductor, comprising several permanent magnets or coiled poles (electromagnets) and a rotor, or an inductor having a cylindrical body and a formed winding are known. by drivers. An air gap exists between the outer periphery of the rotor body and the inner periphery of the stator. The rotor body consisting of a bundle of sheets has longitudinal notches. To form the winding, pin-shaped conductors are threaded into the notches generally on two separate layers.
Le rotor comporte en outre un collecteur muni de lames électriquement conductrices réalisées en cuivre qui s'étendent côte à côte sur la périphérie externe d'un support réalisé en matériau plastique. Ces lames conductrices sont destinées à coopérer avec des balais du moteur électrique. The rotor further comprises a collector provided with electrically conductive blades made of copper which extend side by side on the outer periphery of a support made of plastic material. These conductive blades are intended to cooperate with brushes of the electric motor.
Chacune des lames comprend un logement dans lequel au moins une extrémité des conducteurs du bobinage est positionnée pour être en contact avec la lame correspondante. La liaison entre les lames et les conducteurs est généralement effectuée par soudage. Each of the blades comprises a housing in which at least one end of the winding conductors is positioned to be in contact with the corresponding blade. The connection between the blades and the conductors is generally performed by welding.
Une étude du procédé d'assemblage de conducteurs en aluminium sur le collecteur a mis en évidence un risque important de corrosion de la liaison entre les lames et les extrémités des conducteurs de bobinage. Cette corrosion est susceptible d'engendrer une fragilité mécanique et une augmentation de résistance électrique, voire une isolation électrique au niveau des connexions. Ce risque est d'autant plus important dans le cas d'une atmosphère saline. A study of the process of assembling aluminum conductors on the collector has revealed a significant risk of corrosion of the connection between the blades and the ends of the winding conductors. This corrosion is likely to cause mechanical fragility and an increase in electrical resistance, or electrical insulation at the connections. This risk is even more important in the case of a saline atmosphere.
L'invention vise à remédier efficacement à cet inconvénient en proposant un rotor de démarreur pour véhicule automobile comprenant: - un corps et un bobinage formé par des conducteurs en aluminium installés dans des encoches dudit corps, The invention aims to effectively remedy this disadvantage by proposing a starter rotor for a motor vehicle comprising: a body and a coil formed by aluminum conductors installed in notches of said body,
- un collecteur comprenant des lames de contact en cuivre et un support en matériau isolant,  a collector comprising copper contact strips and a support made of insulating material,
- lesdites lames de contact étant isolées les unes des autres par une partie dudit support, said contact blades being isolated from each other by a part of said support,
- lesdites lames de contact comportant chacune une première portion destinée à être en contact avec des balais et une deuxième portion comportant un logement recevant une extrémité d'au moins un conducteur, caractérisé en ce qu'une couche d'un alliage est interposé dans ledit logement entre chaque conducteur et chaque lame de contact correspondante, ledit alliage étant un alliage conducteur ayant des propriétés physiques pour réduire un couplage électrochimique entre le cuivre et l'aluminium. L'invention permet ainsi de rompre le contact direct entre le cuivre du collecteur et l'aluminium des conducteurs, ce qui permet de limiter la corrosion de la liaison entre les lames de contact et les extrémités des conducteurs de bobinage. On augmente ainsi la durée de vie du démarreur.  said contact blades each comprising a first portion intended to be in contact with brushes and a second portion comprising a housing receiving an end of at least one conductor, characterized in that a layer of an alloy is interposed in said a housing between each conductor and each corresponding contact blade, said alloy being a conductive alloy having physical properties for reducing electrochemical coupling between copper and aluminum. The invention thus makes it possible to break the direct contact between the copper of the collector and the aluminum of the conductors, which makes it possible to limit the corrosion of the connection between the contact strips and the ends of the winding conductors. This increases the life of the starter.
Selon une réalisation, ledit alliage comprend de l'étain. Cela permet d'avoir un alliage qui a de bonne propriété concernant la corrosion évitant l'augmentation de la résistance électrique entre le cuivre et l'aluminium. In one embodiment, said alloy comprises tin. This makes it possible to have an alloy that has good property concerning corrosion avoiding the increase of the electrical resistance between copper and aluminum.
Selon une réalisation, la couche d'alliage recouvre au moins un tronçon dénudé du conducteur dont la longueur est de préférence supérieure à la longueur du tronçon du conducteur situé dans le logement correspondant. Cela permet d'assurer que la partie du tronçon dénudé ne soit en contact avec le collecteur directement. According to one embodiment, the alloy layer covers at least one stripped portion of the conductor whose length is preferably greater than the length of the conductor section located in the corresponding housing. This makes it possible to ensure that the portion of the stripped section does not come into contact with the collector directly.
Selon une réalisation, chaque première portion desdites lames de contact s'étend axialement par rapport à un axe dudit rotor. Cela permet aux poussières d'usure des balais de s'évacuer par la force centrifuge. Selon une réalisation, chaque première portion desdites lames de contact s'étend radialement par rapport à un axe dudit rotor. Cela permet d'avoir un démarreur d'encombrement axial plus réduit. Selon une réalisation, ledit logement est fermé au moins en partie par des bords de lames de contact rabattues vers l'au moins un conducteur. Cela permet d'assurer le contact électrique entre le collecteur le conducteur revêtu de l'alliage et de maintenir les conducteurs dans les encoches malgré la force centrifuge. According to one embodiment, each first portion of said contact blades extends axially with respect to an axis of said rotor. This allows the wear dust of the brushes to escape by centrifugal force. According to one embodiment, each first portion of said contact blades extends radially with respect to an axis of said rotor. This makes it possible to have a lower axial size starter. According to one embodiment, said housing is closed at least in part by edges of contact blades folded towards the at least one conductor. This makes it possible to ensure electrical contact between the collector and the conductor coated with the alloy and to keep the conductors in the slots despite the centrifugal force.
Selon une réalisation, lesdites deuxièmes portions desdites lames de contact comportent chacune des traces de déformation à chaud. Cela permet d'améliorer le rabattage de la lame sur le conducteur. En effet, il y a besoin de moins de force lors d'un poinçonnage à chaud qu'à froid. Selon une réalisation, ladite couche d'alliage comporte du bronze et de l'étain. Cela permet pour certain moteur électrique dissipant non suffisamment les calories, de résister à une température de fusion de l'étain lors d'un fonctionnement à haute température par exemple du à l'utilisation intensive d'un démarreur par exemple dans un embouteillage. Selon une réalisation, ledit au moins un conducteur comprend au moins un tronçon dénudé ayant une longueur supérieure à une longueur d'un tronçon dudit conducteur situé dans ledit logement de ladite deuxième portion de ladite lame de contact correspondante, et en ce que au moins ledit tronçon dénudé est recouvert dudit alliage. Cela permet d'assurer que toute la partie du tronçon dénudée en contact avec le cuivre soit recouvert de l'étain afin d'éviter une corrosion. According to one embodiment, said second portions of said contact blades each comprise traces of hot deformation. This improves the folding of the blade on the driver. Indeed, there is need for less force when punching hot than cold. In one embodiment, said alloy layer comprises bronze and tin. This allows for a certain electric motor not sufficiently dissipating the calories, to withstand a melting temperature of the tin during operation at high temperature for example due to the intensive use of a starter for example in a traffic jam. According to one embodiment, said at least one conductor comprises at least one bare section having a length greater than a length of a portion of said conductor located in said housing of said second portion of said corresponding contact blade, and in that said at least one bare section is covered with said alloy. This ensures that the entire bare section of copper contact is covered with tin to prevent corrosion.
Selon une réalisation, ledit au moins un conducteur comporte une couche d'aluminium anodisée et en ce que ledit tronçon dénudé est dépourvu de cette couche d'aluminium anodisée. Cela permet d'éviter d'avoir à ajouter une résine sur le conducteur pour l'isoler électriquement du paquet de tôle. According to one embodiment, said at least one conductor comprises an anodized aluminum layer and in that said stripped section is devoid of this anodized aluminum layer. This avoids having to add a resin on the conductor to electrically isolate it from the sheet package.
Selon une réalisation, ledit au moins un conducteur comporte une couche d'émail ou de résine par exemple d'époxy et en ce que ledit tronçon dénudé est dépourvu de cette couche d'émail. According to one embodiment, said at least one conductor comprises a layer of enamel or resin for example epoxy and in that said bare section is devoid of this layer of enamel.
Selon une réalisation, une épaisseur de ladite couche d'alliage est comprise entre 3μηη et 20μηη et particulièrement entre 5 m et 12 μιτι. L'invention a également pour objet un démarreur de moteur thermique de véhicule automobile comportant un rotor tel que précédemment défini. According to one embodiment, a thickness of said alloy layer is between 3μηη and 20μηη and particularly between 5 m and 12 μιτι. The invention also relates to a motor vehicle engine starter having a rotor as previously defined.
Selon une autre invention qui vise à remédier efficacement à cet inconvénient en proposant un rotor de démarreur pour véhicule automobile comprenant: According to another invention which aims to effectively remedy this disadvantage by proposing a starter rotor for a motor vehicle comprising:
- un corps et un bobinage formé par des conducteurs en aluminium installés dans des encoches dudit corps,  a body and a coil formed by aluminum conductors installed in notches of said body,
- un collecteur comprenant des lames de contact en cuivre et un support en matériau isolant,  a collector comprising copper contact strips and a support made of insulating material,
- lesdites lames de contact étant isolées les unes des autres par une partie dudit support,  said contact blades being isolated from each other by a part of said support,
- lesdites lames de contact comportant chacune une première portion s'étendant axialement destinée à être en contact avec des balais et une deuxième portion comportant un logement recevant une extrémité d'au moins un conducteur,  said contact blades each comprising a first axially extending portion intended to be in contact with brushes and a second portion comprising a housing receiving an end of at least one conductor,
caractérisé en ce qu'une couche d'un alliage recouvre au moins des faces de ladite lame de contact formant ledit logement et en ce que ladite couche d'alliage est en contact avec ledit au moins un conducteur en aluminium, ledit alliage étant un alliage conducteur ayant des propriétés physiques pour réduire un couplage électrochimique entre le cuivre et l'aluminium. characterized in that a layer of an alloy covers at least faces of said contact blade forming said housing and in that said alloy layer is in contact with said at least one aluminum conductor, said alloy being an alloy conductor having physical properties for reducing electrochemical coupling between copper and aluminum.
L'invention permet ainsi de rompre le contact direct entre le cuivre du collecteur et l'aluminium des conducteurs, ce qui permet de limiter la corrosion de la liaison entre les lames de contact et les extrémités des conducteurs de bobinage. On augmente ainsi la durée de vie du démarreur. The invention thus makes it possible to break the direct contact between the copper of the collector and the aluminum of the conductors, which makes it possible to limit the corrosion of the connection between the contact strips and the ends of the winding conductors. This increases the life of the starter.
Selon une réalisation, une face des lames de contact en vis-à-vis dudit corps de rotor est recouverte de ladite couche d'alliage. Cela permet d'empêcher la corrosion sur cette face du collecteur qui est difficile d'accès lorsque les conducteurs sont dans les encoches. Selon une réalisation, la totalité des faces des lames autres que les faces en contact avec ledit support dudit collecteur sont recouvertes d'une couche d'alliage. Cela permet d'assurer d'avoir l'alliage entre les conducteur et les lames. According to one embodiment, a face of the contact blades vis-à-vis said rotor body is covered with said alloy layer. This prevents corrosion on this face of the collector which is difficult to access when the conductors are in the notches. According to one embodiment, all the faces of the blades other than the faces in contact with said support of said collector are covered an alloy layer. This ensures the alloy between the conductor and the blades.
Selon une réalisation, ledit alliage comprend de l'étain. In one embodiment, said alloy comprises tin.
Selon une réalisation, chaque première portion desdites lames de contact s'étend axialement par rapport à un axe dudit rotor. Cela permet aux poussières d'usure des balais de s'évacuer par la force centrifuge. According to one embodiment, each first portion of said contact blades extends axially with respect to an axis of said rotor. This allows the wear dust of the brushes to escape by centrifugal force.
Selon une réalisation, chaque première portion desdites lames de contact s'étend radialement par rapport à un axe dudit rotor. Cela permet d'avoir un démarreur d'encombrement axial plus réduit. According to one embodiment, each first portion of said contact blades extends radially with respect to an axis of said rotor. This makes it possible to have a lower axial size starter.
Selon une réalisation, ledit logement est fermé au moins en partie par des bords de lames de contact rabattues vers l'au moins un conducteur. Cela permet d'assurer le contact électrique entre le collecteur le conducteur revêtu de l'alliage et de maintenir les conducteurs dans les encoches malgré la force centrifuge. According to one embodiment, said housing is closed at least in part by edges of contact blades folded towards the at least one conductor. This makes it possible to ensure electrical contact between the collector and the conductor coated with the alloy and to keep the conductors in the slots despite the centrifugal force.
Selon une réalisation, lesdites deuxièmes portions desdites lames de contact comportent chacune des traces de déformation à chaud. Cela permet d'améliorer le rabattage de la lame sur le conducteur. En effet, il y a besoin de moins de force lors d'un poinçonnage à chaud qu'à froid. Selon une réalisation, ladite couche d'alliage comporte du bronze et de l'étain. Cela permet pour certain moteur électrique dissipant non suffisamment les calories, de résister à une température de fusion de l'étain lors d'un fonctionnement à haute température par exemple du à l'utilisation intensive d'un démarreur par exemple dans un embouteillage. Selon une réalisation, une épaisseur de ladite couche d'alliage est comprise entre 8μηη et 30μηη et plus particulièrement entre 12 m et 20 μιτι. En effet en dessous de 8 μιτι il y a un risque, lors de l'insertion du conducteur dans l'encoche, que l'étain s'enlève et donc qu'il y a un contact direct entre aluminium et cuivre. En effet, au dessus de 12 μιτι, il n'y a plus de risque de contact direct entre l'aluminium et le cuivre. L'invention sera mieux comprise à la lecture de la description qui suit et à l'examen des figures qui l'accompagnent. Ces figures ne sont données qu'à titre illustratif mais nullement limitatif de l'invention. La figure 1 montre une vue en perspective d'un rotor de démarreur selon la présente invention; According to one embodiment, said second portions of said contact blades each comprise traces of hot deformation. This improves the folding of the blade on the driver. Indeed, there is need for less force when punching hot than cold. In one embodiment, said alloy layer comprises bronze and tin. This allows for a certain electric motor not sufficiently dissipating the calories, to withstand a melting temperature of the tin during operation at high temperature for example due to the intensive use of a starter for example in a traffic jam. According to one embodiment, a thickness of said alloy layer is between 8μηη and 30μηη and more particularly between 12 m and 20 μιτι. Indeed below 8 μιτι there is a risk, when inserting the conductor in the notch, that the tin is removed and therefore there is a direct contact between aluminum and copper. Indeed, above 12 μιτι, there is more risk of direct contact between aluminum and copper. The invention will be better understood on reading the description which follows and on examining the figures which accompany it. These figures are given for illustrative but not limiting of the invention. Figure 1 shows a perspective view of a starter rotor according to the present invention;
La figure 2 est une vue de côté du rotor de démarreur selon la présente invention; Figure 2 is a side view of the starter rotor according to the present invention;
La figure 3 est une vue en coupe longitudinale du rotor de démarreur selon la présente invention; Figure 3 is a longitudinal sectional view of the starter rotor according to the present invention;
La figure 4 est une représentation schématique illustrant les deux couches de conducteurs positionnées à l'intérieur des encoches du corps du rotor; Figure 4 is a schematic representation illustrating the two layers of conductors positioned within the notches of the rotor body;
La figure 5 est une représentation schématique illustrant la liaison entre des conducteurs et une lame de contact correspondante dans un rotor de démarreur selon la présente invention; Fig. 5 is a schematic representation illustrating the connection between conductors and a corresponding contact blade in a starter rotor according to the present invention;
La figure 6 est une représentation schématique d'un conducteur utilisé dans le rotor de démarreur selon la présente invention. Figure 6 is a schematic representation of a conductor used in the starter rotor according to the present invention.
Les éléments identiques, similaires ou analogues conservent les mêmes références d'une figure à l'autre. Les figures 1 à 3 montrent un rotor 10 d'axe X comportant un corps 1 1 monté sur un arbre 12. Ce corps 1 1 en forme de paquet de tôles feuilletées présente une périphérie externe de forme cylindrique. Des encoches 14 sont ménagées longitudinalement à la périphérie externe du corps 1 1 . Pour former le bobinage, un ensemble de conducteurs 13 sont enfilés à l'intérieur de ces encoches 14. Identical, similar or similar elements retain the same references from one figure to another. Figures 1 to 3 show an X-axis rotor 10 having a body 1 1 mounted on a shaft 12. This body 1 1 in the form of pack of laminated sheets has an outer periphery of cylindrical shape. Notches 14 are formed longitudinally at the outer periphery of the body 1 1. To form the winding, a set of conductors 13 are threaded inside these notches 14.
Plus précisément, comme visible sur la figure 4, chaque conducteur 13 réalisé en aluminium comprend en surface une couche d'aluminium anodisé 39. Chaque conducteur 13 est en outre revêtu d'une couche électriquement isolante 15, telle que de l'émail pour son isolation. Chaque conducteur 13 présente deux branches 131 , 132 reliées par un fond 133 de manière à former un U (cf. figure 6). Les conducteurs 13 sont enfilés à l'intérieur des encoches 14 sur deux couches distinctes : la couche supérieure et la couche inférieure. Si une des branches 131 , 132 est positionnée dans la couche inférieure d'une encoche donnée alors l'autre branche 131 , 132 se situe dans la couche supérieure d'une autre encoche et inversement. La section des conducteurs 13 peut être ronde, carrée, ou rectangulaire. Les parties des conducteurs 13 s'étendant en saillie par rapport aux faces d'extrémités du corps 1 1 du rotor 10 forment les chignons du bobinage. Un isolant d'encoche 18 est positionné autour des branches 131 , 132 des conducteurs 13. En l'occurrence, cet isolant 18 présente une section en forme de S. Cet isolant 18 permet de ne pas blesser les conducteurs 13 lors de leur montage dans le corps 1 1 formé par le paquet de tôles du rotor 10 doté par définition de bavures. Cela isole également électriquement les conducteurs 13 par rapport au paquet de tôles relié à la masse via le carter du démarreur. Le jeu entre l'isolant 18 et les bords des encoches 14 est comblé par un vernis d'imprégnation. More specifically, as can be seen in FIG. 4, each conductor 13 made of aluminum has an anodized aluminum surface layer 39 at its surface. Each conductor 13 is further coated with an electrically insulating layer 15, such as enamel for its insulation. Each driver 13 has two branches 131, 132 connected by a bottom 133 so as to form a U (see Figure 6). The conductors 13 are threaded inside the notches 14 on two distinct layers: the upper layer and the lower layer. If one of the branches 131, 132 is positioned in the lower layer of a given notch then the other leg 131, 132 is in the upper layer of another notch and vice versa. The section of the conductors 13 may be round, square, or rectangular. The portions of the conductors 13 projecting from the end faces of the body 1 1 of the rotor 10 form the buns of the winding. A notch insulator 18 is positioned around the branches 131, 132 of the conductors 13. In this case, this insulator 18 has an S-shaped section. This insulator 18 makes it possible not to injure the conductors 13 during their assembly in the body 1 1 formed by the bundle of sheets of the rotor 10 provided by definition of burrs. This also electrically insulates the conductors 13 from the grounded package of sheets via the starter housing. The clearance between the insulator 18 and the edges of the notches 14 is filled with an impregnating varnish.
Le rotor 10 comporte en outre un collecteur 19 muni de lames 20 électriquement conductrices qui s'étendent côte à côte sur une périphérie externe d'un support 23 électriquement isolant bien visible sur la figure 3. Les lames de contact 20 sont isolées les unes des autres par une partie du support 23. Le support 23 solidaire de l'arbre est, pour une bonne tenue en température, en matière plastique thermodurcissable, telle qu'une matière plastique phénolique thermodurcissable par exemple de la bakélite. Les lames conductrices 20 comportent chacune une première portion 21 s'étendant sensiblement axialement suivant l'axe X du rotor 10 et destinée à être en contact avec des balais du moteur électrique orientés radialement (non représentés). Les lames conductrices 20 comportent également une deuxième portion 22 ayant une orientation radiale par rapport à l'axe X du rotor. L'ensemble des deuxièmes portions 22 forme le talon 28 du collecteur 19. The rotor 10 further comprises a collector 19 provided with electrically conductive blades 20 which extend side by side on an outer periphery of an electrically insulating support 23 which is clearly visible in FIG. 3. The contact strips 20 are isolated from each other. other by a portion of the support 23. The support 23 secured to the shaft is, for good temperature resistance, thermosetting plastic material, such as a thermosetting phenolic plastic material for example Bakelite. The conductive blades 20 each comprise a first portion 21 extending substantially axially along the X axis of the rotor 10 and intended to be in contact with radially oriented electric motor brushes (not shown). The conductive blades 20 also comprise a second portion 22 having a radial orientation with respect to the X axis of the rotor. The set of second portions 22 forms the heel 28 of the collector 19.
Chaque deuxième portion de lame 22 comprend un logement 25 dans lequel deux tronçons 41 des conducteurs 13 du bobinage du rotor 10 sont positionnés pour être en contact avec la lame conductrice 20 correspondante (cf. figure 5). Les tronçons 41 positionnés à l'intérieur des logements 25 sont constituées par une partie des extrémités libres de branches 131 , 132 de deux conducteurs différents. Comme cela est illustré sur la figure 5, une couche 35 d'un alliage est interposée dans le logement 25 entre chaque conducteur 13 et la lame de contact 20 correspondante. L'alliage est un alliage conducteur ayant des propriétés physiques pour réduire un couplage électrochimique entre le cuivre (des lames 20) et l'aluminium (des conducteurs 13). De préférence, l'alliage comprend de l'étain. Avantageusement, une épaisseur de la couche d'alliage 35 est comprise entre 3μηη et 20μηη et particulièrement entre 5 μιτι et 12 m Each second blade portion 22 comprises a housing 25 in which two sections 41 of the conductors 13 of the rotor winding 10 are positioned to be in contact with the corresponding conductive blade 20 (see Figure 5). The sections 41 positioned inside the housings 25 are constituted by a portion of the free ends of branches 131, 132 of two different conductors. As illustrated in FIG. 5, a layer 35 of an alloy is interposed in the housing 25 between each conductor 13 and the corresponding contact blade 20. The alloy is a conductive alloy having physical properties to reduce electrochemical coupling between copper (blades 20) and aluminum (conductors 13). Preferably, the alloy comprises tin. Advantageously, a thickness of the alloy layer 35 is between 3μηη and 20μηη and particularly between 5 μιτι and 12 m
Comme on peut le voir sur la figure 6, la couche d'alliage 35 recouvre au moins un tronçon dénudé 40 du conducteur 13 dont la longueur est de préférence supérieure à la longueur du tronçon 41 du conducteur situé dans le logement 25 correspondant. Dans un exemple de réalisation, le conducteur 13 est dénudé à ses extrémités à l'aide de papier de verre ou d'une pince dénudeuse sur une longueur de l'ordre de 1 cm. Le tronçon dénudé 40 est ainsi dépourvu de la fine couche d'aluminium anodisée 39 isolante et de la couche d'émail 15, de telle façon que la couche d'alliage 35 est déposée directement sur le cuivre constituant le conducteur. A cette fin, les conducteurs 13 sont trempés par exemple dans de l'étain chauffé à sa température de fusion (de l'ordre de 230 degrés Celsius), lequel va glisser sur l'émail 15 pour recouvrir uniquement les tronçons dénudés 40 des conducteurs 13. As can be seen in FIG. 6, the alloy layer 35 covers at least one stripped section 40 of the conductor 13, the length of which is preferably greater than the length of the section 41 of the conductor located in the corresponding housing 25. In an exemplary embodiment, the conductor 13 is stripped at its ends with the aid of sandpaper or a stripping plier on a length of the order of 1 cm. The stripped portion 40 is thus devoid of the thin insulating anodized aluminum layer 39 and the enamel layer 15, so that the alloy layer 35 is deposited directly on the copper constituting the conductor. For this purpose, the conductors 13 are tempered, for example, in tin heated to its melting point (of the order of 230.degree. C.), which will slide on the enamel 15 to cover only the bare sections 40 of the conductors. 13.
Une fois la couche d'alliage 35 déposée sur les tronçons dénudés 40 des conducteurs 13, les liaisons électriques entre les conducteurs 13 et les deuxième portions des lames 22 sont de préférence réalisées par un procédé dit de poinçonnage à chaud consistant à chauffer le talon 28 au moyen d'une électrode de manière à rabattre un bord des portions de lame 22 après insertion des tronçons 41 des conducteurs 13 dans les logements 25. Comme cela est montré sur la figure 5, les conducteurs 13 sont alors retenus dans chaque logements 25 par de la matière 45 des deuxièmes portions de lame 22 déformée à chaud vers les conducteurs 13 de manière à fermer le logement 25. Once the alloy layer 35 has been deposited on the stripped portions 40 of the conductors 13, the electrical connections between the conductors 13 and the second portions of the blades 22 are preferably made by a so-called hot punching method of heating the bead 28. by means of an electrode so as to fold down an edge of the blade portions 22 after insertion of the sections 41 of the conductors 13 into the housings 25. As shown in FIG. 5, the conductors 13 are then retained in each housing 25 by material 45 of the second blade portions 22 deformed hot to the conductors 13 so as to close the housing 25.
En variante, les liaisons électriques entre les conducteurs 13 et les lames 20 sont réalisées par un procédé de soudure par ultrason ou par résistance. Dans ce type de procédé qui a tendance à mélanger les matières en présence, la couche d'alliage 35 comporte de l'étain et du bronze résultant du mélange entre une partie de l'étain recouvrant le conducteur et une partie du cuivre de la lame 20 correspondante. Alternativement, les conducteurs 13 sont retenus dans les logements 25 par poinçonnage. Alternatively, the electrical connections between the conductors 13 and the blades 20 are performed by a method of welding by ultrasound or resistance. In this type of process, which tends to mix the materials in the presence, the alloy layer 35 comprises tin and bronze resulting from mixing between a portion of the tin covering the conductor and a part of the copper of the blade. Corresponding. Alternatively, the conductors 13 are retained in the housing 25 by punching.
Il est à noter que le reste des liaisons électriques entre les fils 13 et les lamesIt should be noted that the rest of the electrical connections between the wires 13 and the blades
20 (le diamètre extérieur et la face opposée du talon 28 tournée vers le bobinage), sont protégées par le vernis déposé lors de l'étape d'imprégnation du bobinage. Dans un autre mode de réalisation dit de type tambour, la première portion20 (the outside diameter and the opposite face of the heel 28 turned towards the winding), are protected by the varnish deposited during the step of impregnation of the winding. In another embodiment of the drum type, the first portion
21 de chaque lame de contact 20 s'étend radialement par rapport à l'axe X du rotor 10 de manière à coopérer avec des balais orientés axialement par rapport à l'axe X. 21 of each contact blade 20 extends radially relative to the axis X of the rotor 10 so as to cooperate with brushes oriented axially with respect to the axis X.
Afin d'assurer une retenue radiale des conducteurs 13 pour éviter que les effets de la force centrifuge s'exercent sur les liaisons entre les extrémités des conducteurs 13 et les lames conductrices 20 ainsi que sur les chignons du bobinage, des frettes 30, 31 , 32 en matière électriquement isolante, bien visible sur la figure 1 , sont montées serrées autour des liaisons électriques et des chignons du bobinage situés de part et d'autre du corps du rotor 1 1 . Le rotor 10 pourra comporter en outre à une extrémité de son arbre 12 une roue d'engrenage 33 située du côté opposé du collecteur 19 et destinée à former un planétaire dans un système de réduction de vitesse à train épicycloïdal d'un démarreur, comme décrit par exemple dans le document FR2787833. En variante, on positionne un seul conducteur 13 de bobinage par logement 25. L'invention a également pour objet le démarreur équipé du rotor 10 précédemment décrit. In order to ensure a radial retention of the conductors 13 to prevent the effects of the centrifugal force on the connections between the ends of the conductors 13 and the conductive blades 20 as well as on the coil windings, frets 30, 31, 32 electrically insulating material, clearly visible in Figure 1, are mounted tightly around the electrical connections and winding bignons located on either side of the body of the rotor 1 January. The rotor 10 may further comprise at one end of its shaft 12 a gear wheel 33 located on the opposite side of the collector 19 and intended to form a sun gear in a planetary gear reduction system of a starter, as described for example in the document FR2787833. In a variant, a single winding conductor 13 is positioned per housing 25. The invention also relates to the starter equipped with the rotor 10 described above.
Le démarreur comprend en outre un stator comprenant un bobinage ou des aimants pour former les pôles de l'inducteur. Le démarreur comprend en outre un actionneur comprenant une plaquette de contact mobile qui se déplace jusqu'à une position fermeture reliant deux bornes de contact dont une raccordée à la batterie et l'autre raccordée aux balais du collecteur et au bobinage inducuteur si le stator comprend un bobinage inducteur. Selon une autre invention, le rotor de démarreur pour véhicule automobile comprend: The starter further comprises a stator comprising a coil or magnets for forming the poles of the inductor. The starter further comprises an actuator comprising a movable contact plate that moves to a closed position connecting two contact terminals, one of which is connected to the battery and the other connected to the collector brushes and to the induction coil if the stator comprises an inductor winding. According to another invention, the starter rotor for a motor vehicle comprises:
- un corps et un bobinage formé par des conducteurs en aluminium installés dans des encoches dudit corps,  a body and a coil formed by aluminum conductors installed in notches of said body,
- un collecteur comprenant des lames de contact en cuivre et un support en matériau isolant,  a collector comprising copper contact strips and a support made of insulating material,
- lesdites lames de contact étant isolées les unes des autres par une partie dudit support,  said contact blades being isolated from each other by a part of said support,
- lesdites lames de contact comportant chacune une première portion s'étendant axialement destinée à être en contact avec des balais et une deuxième portion comportant un logement recevant une extrémité d'au moins un conducteur,  said contact blades each comprising a first axially extending portion intended to be in contact with brushes and a second portion comprising a housing receiving an end of at least one conductor,
caractérisé en ce qu'une couche d'un alliage recouvre au moins des faces de ladite lame de contact formant ledit logement et en ce que ladite couche d'alliage est en contact avec ledit au moins un conducteur en aluminium, ledit alliage étant un alliage conducteur ayant des propriétés physiques pour réduire un couplage électrochimique entre le cuivre et l'aluminium. characterized in that a layer of an alloy covers at least faces of said contact blade forming said housing and in that said alloy layer is in contact with said at least one aluminum conductor, said alloy being an alloy conductor having physical properties for reducing electrochemical coupling between copper and aluminum.
L'invention permet ainsi de rompre le contact direct entre le cuivre du collecteur et l'aluminium des conducteurs, ce qui permet de limiter la corrosion de la liaison entre les lames de contact et les extrémités des conducteurs de bobinage. On augmente ainsi la durée de vie du démarreur. Par alliage on entend un alliage qui ne comprend pas une majorité d'aluminium ou/et de cuivre. Selon une réalisation, une face des lames de contact en vis-à-vis dudit corps de rotor est recouverte de ladite couche d'alliage. Cela permet d'empêcher la corrosion sur cette face du collecteur qui est difficile d'accès lorsque les conducteurs sont dans les encoches. Selon une réalisation, la totalité des faces des lames autres que les faces en contact avec ledit support dudit collecteur sont recouvertes d'une couche d'alliage. Cela permet d'assurer d'avoir l'alliage entre les conducteur et les lames. The invention thus makes it possible to break the direct contact between the copper of the collector and the aluminum of the conductors, which makes it possible to limit the corrosion of the connection between the contact strips and the ends of the winding conductors. This increases the life of the starter. By alloy is meant an alloy that does not include a majority of aluminum and / or copper. According to one embodiment, a face of the contact blades vis-à-vis said rotor body is covered with said alloy layer. This prevents corrosion on this face of the collector which is difficult to access when the conductors are in the notches. According to one embodiment, all the faces of the blades other than the faces in contact with said support of said collector are covered with an alloy layer. This ensures the alloy between the conductor and the blades.
Selon une réalisation, ledit alliage comprend de l'étain. Selon une réalisation, chaque première portion desdites lames de contact s'étend axialement par rapport à un axe dudit rotor. Cela permet aux poussières d'usure des balais de s'évacuer par la force centrifuge. In one embodiment, said alloy comprises tin. According to one embodiment, each first portion of said contact blades extends axially with respect to an axis of said rotor. This allows the wear dust of the brushes to escape by centrifugal force.
Selon une réalisation, chaque première portion desdites lames de contact s'étend radialement par rapport à un axe dudit rotor. Cela permet d'avoir un démarreur d'encombrement axial plus réduit. According to one embodiment, each first portion of said contact blades extends radially with respect to an axis of said rotor. This makes it possible to have a lower axial size starter.
Selon une réalisation, ledit logement est fermé au moins en partie par des bords de lames de contact rabattues vers l'au moins un conducteur. Cela permet d'assurer le contact électrique entre le collecteur le conducteur revêtu de l'alliage et de maintenir les conducteurs dans les encoches malgré la force centrifuge. According to one embodiment, said housing is closed at least in part by edges of contact blades folded towards the at least one conductor. This makes it possible to ensure electrical contact between the collector and the conductor coated with the alloy and to keep the conductors in the slots despite the centrifugal force.
Selon une réalisation, lesdites deuxièmes portions desdites lames de contact comportent chacune des traces de déformation à chaud. Cela permet d'améliorer le rabattage de la lame sur le conducteur. En effet, il y a besoin de moins de force lors d'un poinçonnage à chaud qu'à froid. According to one embodiment, said second portions of said contact blades each comprise traces of hot deformation. This improves the folding of the blade on the driver. Indeed, there is need for less force when punching hot than cold.
Selon une réalisation, ladite couche d'alliage comporte du bronze et de l'étain. Cela permet pour certain moteur électrique dissipant non suffisamment les calories, de résister à une température de fusion de l'étain lors d'un fonctionnement à haute température par exemple du à l'utilisation intensive d'un démarreur par exemple dans un embouteillage. Selon une réalisation, une épaisseur de ladite couche d'alliage est comprise entre 8μηη et 30μηη et plus particulièrement entre 12 μιτι et 20 μιτι. En effet en dessous de 8 μιτι il y a un risque, lors de l'insertion du conducteur dans l'encoche, que l'étain s'enlève et donc qu'il y a un contact direct entre aluminium et cuivre. En effet, au dessus de 12 μιτι, il n'y a plus de risque de contact direct entre l'aluminium et le cuivre. In one embodiment, said alloy layer comprises bronze and tin. This allows for a certain electric motor not sufficiently dissipating the calories, to withstand a melting temperature of the tin during operation at high temperature for example due to the intensive use of a starter for example in a traffic jam. According to one embodiment, a thickness of said alloy layer is between 8μηη and 30μηη and more particularly between 12 μιτι and 20 μιτι. Indeed below 8 μιτι there is a risk, when inserting the conductor in the notch, that the tin is removed and therefore there is a direct contact between aluminum and copper. Indeed, above 12 μιτι, there is more risk of direct contact between aluminum and copper.
Bien entendu, la description qui précède a été donnée à titre d'exemple uniquement et ne limite pas le domaine de l'invention dont on ne sortirait pas en remplaçant les différents éléments par tous autres équivalents. Of course, the foregoing description has been given by way of example only and does not limit the scope of the invention which would not be overcome by replacing the different elements by any other equivalent.

Claims

REVENDICATIONS
1 . Rotor (10) de démarreur pour véhicule automobile comprenant:1. Motor vehicle starter rotor (10) comprising:
- un corps (1 1 ) et un bobinage formé par des conducteurs (13) en aluminium installés dans des encoches (14) dudit corps (1 1 ), a body (1 1) and a coil formed by aluminum conductors (13) installed in notches (14) of said body (1 1),
- un collecteur (19) comprenant des lames de contact (20) en cuivre et un support (23) en matériau isolant,  a collector (19) comprising copper contact strips (20) and a support (23) made of insulating material,
- lesdites lames de contact (20) étant isolées les unes des autres par une partie dudit support (23),  said contact blades (20) being isolated from one another by a portion of said support (23),
- lesdites lames de contact (20) comportant chacune une première portion (21 ) destinée à être en contact avec des balais et une deuxième portion (22) comportant un logement (25) recevant une extrémité d'au moins un conducteur (13),  said contact blades (20) each having a first portion (21) intended to be in contact with brushes and a second portion (22) comprising a housing (25) receiving an end of at least one conductor (13),
caractérisé en ce qu'une couche (35) d'un alliage est interposé dans ledit logement (25) entre chaque conducteur (13) et chaque lame de contact (20) correspondante, ledit alliage étant un alliage conducteur ayant des propriétés physiques pour réduire un couplage électrochimique entre le cuivre et l'aluminium.  characterized in that a layer (35) of an alloy is interposed in said housing (25) between each conductor (13) and each corresponding contact blade (20), said alloy being a conductive alloy having physical properties to reduce electrochemical coupling between copper and aluminum.
2. Rotor selon la revendication 1 , caractérisé en ce que ledit alliage comprend de l'étain. 2. Rotor according to claim 1, characterized in that said alloy comprises tin.
3. Rotor selon la revendication 1 ou 2, caractérisé en ce que chaque première portion (21 ) desdites lames de contact (20) s'étend axialement par rapport à un axe (X) dudit rotor (10). 3. Rotor according to claim 1 or 2, characterized in that each first portion (21) of said contact blades (20) extends axially with respect to an axis (X) of said rotor (10).
4. Rotor selon la revendication 1 ou 2, caractérisé en ce que chaque première portion (21 ) desdites lames de contact (20) s'étend radialement par rapport à un axe (X) dudit rotor (10). 4. Rotor according to claim 1 or 2, characterized in that each first portion (21) of said contact blades (20) extends radially relative to an axis (X) of said rotor (10).
5. Rotor selon l'une quelconque des revendications 1 à 4, caractérisé en ce que ledit logement (25) est fermé au moins en partie par des bords de lames de contact (20) rabattues vers l'au moins un conducteur (13). 5. Rotor according to any one of claims 1 to 4, characterized in that said housing (25) is closed at least in part by edges of contact blades (20) folded towards the at least one conductor (13) .
6. Rotor selon l'une quelconque des revendications 1 à 5, caractérisé en ce que lesdites deuxièmes portions (22) desdites lames de contact (20) comportent chacune des traces (45) de déformation à chaud. 6. Rotor according to any one of claims 1 to 5, characterized in that said second portions (22) of said contact blades (20) each comprise traces (45) of hot deformation.
7. Rotor selon l'une quelconque des revendications 1 à 6, caractérisé en ce que ladite couche d'alliage (35) comporte du bronze et de l'étain. 7. Rotor according to any one of claims 1 to 6, characterized in that said alloy layer (35) comprises bronze and tin.
8. Rotor selon l'une quelconque des revendications 1 à 7, caractérisé en ce que ledit au moins un conducteur (13) comprend au moins un tronçon dénudé (40) ayant une longueur supérieure à une longueur d'un tronçon (41 ) dudit conducteur situé dans ledit logement (25) de ladite deuxième portion (22) de ladite lame de contact (20) correspondante, et en ce que au moins ledit tronçon dénudé (40) est recouvert dudit alliage. 8. Rotor according to any one of claims 1 to 7, characterized in that said at least one conductor (13) comprises at least one stripped portion (40) having a length greater than a length of a portion (41) of said conductor located in said housing (25) of said second portion (22) of said corresponding contact blade (20), and in that at least said stripped portion (40) is covered with said alloy.
9. Rotor selon l'une quelconque des revendications 1 à 8, caractérisé en ce que le au moins un conducteur (13) comporte une couche d'aluminium anodisée (39) et en ce que ledit tronçon dénudé (40) est dépourvu de cette couche d'aluminium anodisée (39). 9. Rotor according to any one of claims 1 to 8, characterized in that the at least one conductor (13) comprises an anodized aluminum layer (39) and in that said stripped portion (40) is devoid of this anodized aluminum layer (39).
10. Rotor selon l'une quelconque des revendications 1 à 9, caractérisé en ce que ledit au moins un conducteur comporte une couche d'émail (15) et en ce que ledit tronçon dénudé (40) est dépourvu de cette couche d'émail (15). 10. Rotor according to any one of claims 1 to 9, characterized in that said at least one conductor comprises an enamel layer (15) and in that said stripped portion (40) is devoid of this layer of enamel (15).
1 1 . Rotor selon l'une quelconque des revendications 1 à 10, caractérisé en ce qu'une épaisseur de ladite couche d'alliage (35) est comprise entre 3μηη et 20μηη et particulièrement entre 5 μιτι et 12 μιτι 1 1. Rotor according to any one of claims 1 to 10, characterized in that a thickness of said alloy layer (35) is between 3μηη and 20μηη and particularly between 5 μιτι and 12 μιτι
12. Démarreur de moteur thermique de véhicule automobile comportant un rotor tel que défini selon l'une quelconque des revendications précédentes. 12. Motor vehicle engine starter comprising a rotor as defined in any one of the preceding claims.
PCT/FR2016/052449 2015-09-28 2016-09-27 Corrosion-resistant starter rotor for a motor vehicle WO2017055731A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
FR1559110A FR3041829A1 (en) 2015-09-28 2015-09-28 STARTER ROTOR FOR MOTOR VEHICLE RESISTANT TO CORROSION
FR1559108A FR3041828A1 (en) 2015-09-28 2015-09-28 STARTER ROTOR FOR MOTOR VEHICLE WITH COLLECTOR COVERED AT LEAST IN PART WITH CORROSION-LIMITING ALLOY
FR1559108 2015-09-28
FR1559110 2015-09-28

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WO2017055731A1 true WO2017055731A1 (en) 2017-04-06

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PCT/FR2016/052449 WO2017055731A1 (en) 2015-09-28 2016-09-27 Corrosion-resistant starter rotor for a motor vehicle

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1988006356A1 (en) * 1987-02-12 1988-08-25 Mitsubishi Denki Kabushiki Kaisha Dc motor and manufacturing method therefor
FR2787833A1 (en) 1998-12-23 2000-06-30 Valeo Equip Electr Moteur STARTER FOR A MOTOR VEHICLE WITH GEAR REDUCER COMPRISING TORSION DAMPING MEANS
WO2011098447A2 (en) * 2010-02-12 2011-08-18 Robert Bosch Gmbh Starting device
DE102010064230A1 (en) * 2010-12-28 2012-06-28 Robert Bosch Gmbh Protection device for commutator of electric machine i.e. starter motor, for internal combustion engine of motor car, has switching device formed such that electric contact is completely coverable at front ends of winding elements
WO2015071618A1 (en) * 2013-11-18 2015-05-21 Valeo Equipements Electriques Moteur Low power starter with optimised size for a motor vehicle

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1988006356A1 (en) * 1987-02-12 1988-08-25 Mitsubishi Denki Kabushiki Kaisha Dc motor and manufacturing method therefor
FR2787833A1 (en) 1998-12-23 2000-06-30 Valeo Equip Electr Moteur STARTER FOR A MOTOR VEHICLE WITH GEAR REDUCER COMPRISING TORSION DAMPING MEANS
WO2011098447A2 (en) * 2010-02-12 2011-08-18 Robert Bosch Gmbh Starting device
DE102010064230A1 (en) * 2010-12-28 2012-06-28 Robert Bosch Gmbh Protection device for commutator of electric machine i.e. starter motor, for internal combustion engine of motor car, has switching device formed such that electric contact is completely coverable at front ends of winding elements
WO2015071618A1 (en) * 2013-11-18 2015-05-21 Valeo Equipements Electriques Moteur Low power starter with optimised size for a motor vehicle

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